Liner for spill continment manholes

ABSTRACT

A method of repairing a leaking spill container by lining the existing unit. Additionally the liner can be used to convert a single walled spill container into a double walled spill container.

FIELD OF THE INVENTION

The present invention relates to containment of fluids and, moreparticularly, to the containment of fluids in overfill or spillcontainers.

BACKGROUND OF THE INVENTION

Prior to 1988 the US EPA determined that significant pollution wasoccurring in the US due to fuel leaking from a number of sources atfueling facilities (gas stations). Tanks, piping from tanks todispensers, fuel leaks at the dispensers and fuel discharges caused byoverfilling tanks and from fuel remaining in the filling hoses allcontributed to pollution at fueling facilities. The US EPA establishedguidelines for upgrading fueling facilities including requiring a meansof catching fuel discharged in the process of filling the tanks. Thesecatchment basins came to be know as “Spill Containers”, “SpillContainment Manholes”, “Spill Containment Buckets” and a host of othersimilar descriptions. Some spill containers were and are manufacturedout of welded metal. Other less expensive spill containers were and aremanufactured using a plastic bellows. The plastic bellows style of spillcontainer became the popular choice and is found at most fuelingfacilities today.

Over time spill containers themselves have started leaking. Some Stateshave now regulated the testing and certifying of the spill containers ona periodic basis. As an example, the State of Alabama has startedrequiring that spill containment manholes be hydrostatically tested. Anyleaking spill container must be repaired or replaced or the servicestation can be shut down until the offending spill container can bereplaced. Since the installation of the first spill containment manholesin the late 1980's there has been a need for an inexpensive repair ofleaking spill containers.

Presently the only known solution is to replace the manhole with a newone.

Replacing an existing spill containment manhole is an expensive processrequiring in most instances that at least part of the site be closedwhile repairs are being performed. Excavating equipment is required,concrete must be broken and removed and a new spill container must bepurchased and installed. Delays may be encountered to obtain permits. Myrecent survey, conducted in 2008, of replaced spill containers indicatesthe cost is approximately $4500 per unit. This cost does not account forlost fuel revenues, costs of permits and any clean up costs associatedwith the uncovering of contaminated soils surrounding the leaking spillcontainer.

It would be advantageous to provide a liner that is fuel resistant.

It would also be advantageous to provide a liner that can be made toclosely match the inside of the existing spill container so as tominimize the loss of capacity of the spill container once the liner isin place.

It would also be advantageous to provide a liner that can create a totalseal between the snow plow ring installed on the surface of the fuelingfacility and the riser pipe extending from the fuel tank.

It would also be advantageous if the cost of the liner installed is afraction of replacing the spill container.

It would also be advantageous if the spill container can be repairedwithout breaking concrete or using construction equipment.

It would also be advantageous if the liner could be installed within afew hours by a single technician.

It would also be advantageous if the liner could be coated with a filmof material that is highly chemically resistant to the liquids to beencountered.

It would further be advantageous if the liner could be used to convertan existing single walled spill container to a double walled spillcontainer.

SUMMARY OF THE INVENTION

In accordance with the present invention, there is provided a method ofrepairing a leaking spill containment manhole by lining the existingunit. Additionally the liner can be used to convert a structurally soundsingle walled spill containment manhole into a double walled spillcontainment manhole.

BRIEF DESCRIPTION OF THE DRAWINGS

A complete understanding of the present invention may be obtained byreference to the accompanying drawings, when considered in conjunctionwith the subsequent, detailed description, in which:

FIG. 1 is a cross section view of an existing spill container with aplastic bellows;

FIG. 2 is a cross section view of an existing spill container with ametal body;

FIG. 3 is a cross section view of the components required to manufacturea liner;

FIG. 4 is a cross section view of a bellows style spill container with adrain valve mounted on a tank riser;

FIG. 5 is a cross section view of a bellows style spill container wherefill has been added to cover the irregular shape of the bottom of thespill container;

FIG. 6 is a cross section view of an of the liner showing the coatedsurface, ready to be installed in a bellows style spill container; and

FIG. 7 is a cross section view of a bellows style spill container withthe liner installed.

For purposes of clarity and brevity, like elements and components willbear the same designations and numbering throughout the Figures.

DESCRIPTION OF THE PREFERRED EMBODIMENT

This invention is best understood by referring initially to existingspill containment manholes in FIG. 1 and FIG. 2. FIG. 1 is a crosssection view of a spill containment manhole with a bellows 20 stylebody, a snow plow ring 22 (common to most spill containers), a base 24(common to most spill containers), a drain valve 26 (common to mostspill containers) and a tank riser 28 (common to all spill containers).FIG. 2 is a cross section view of a spill containment manhole with ametal body in lieu of the bellows 20-style body shown if FIG. 1. Thespill containment manhole in FIGS. 1 and 2 are connected to a 4″ tankriser 28 extending from the top of the buried fuel tank. The surface ofa fueling facility is covered with a concrete slab. The snow plow ring22 is mounted more or less flush with the top of the concrete slab.Attached to the snow plow ring 22 is the rest of the spill container.The bellows 20 is normally attached to the underside of the snow plowring 22 by means of bolts through a lip on the top of the bellows 20terminating into the bottom of the snow plow ring 22. The bellows 20 isterminated to the base 24 in any number of manners including bolts, bandclamps or other securing devices. The riser inside the spill containeris terminated into the base 24 of the spill container. Often a drainvalve 26 is installed in the base 24 so that liquids captured in thespill container may be drained into the tank riser 28. All seams orjoints created at the junction of the various components may create leakpaths. Spill containers that incorporate a plastic bellows 20 haveproven to have a high failure rate of the bellows 20 itself. There areat least nine different spill containment manufacturers and each mayhave multiple configurations of their spill containers. It is notnecessary to identify all the permutations that may be encountered inthe field. FIGS. 1 and 2 represent cross sections of typical spillcontainers encountered in the industry. Irrespective of the cause andlocation of a failed, (leaking) spill container or the configuration ofthe spill container, my invention provides means for repairing thesespill containers.

FIG. 3 is a cross section view of the components of a liner 30. When theliner top 12, is joined to the liner bottom 10, the liner 30 is created.In some instances the liner 30 may be manufactured as a singlecomponent. Such a liner 30 could be fitted into FIG. 2. and function asdesigned. However most spill containers have a mouth opening smallerthan the diameter of the bellows 20 section of the spill container asshown in FIG. 1. It is preferred that the liner 30 fit the interiorprofile of the spill container as liner 30 needs to be as large aspossible so as to not unduly reduce the capacity of the spill container.Large “collapsing core” molds could be made to manufacture the variousliners in one piece. It is preferred however, to manufacture the liner30 from two or more segments. It is preferred to manufacture a separateliner bottom 10 and a separate liner top 12 and join the components by asuitable connecting method. In that manner the tooling required to makeall the configurations of liners required can be minimized. The bottomfrom one liner 30 and the top from another liner 30 may be joined toform a third liner 30. In the preferred embodiment, a bonding agent isused to bond the liner 30 to the snow plow ring 22 and to the tank riser28. While bonding is not required it is a highly recommended procedurethat assures a long lasting product requiring little maintenance. Theliner 30 material should be chemically resistant to the liquids to beencountered. The liner 30 should be able to be bonded a to the matingspill container and tank riser 28 surfaces as well as being able to bebonded together. One such material that has been tested by UnderwritersLaboratories for use in secondary containment applications at fuelingsites is Pellethane 2355-85ABR available from Dow Chemical Co.Additionally the liner 30 may have a coating 36 applied. A suitablecoating 36 material is used to make the liner 30 chemically moreresistant to the specific fluids to be contained. A polysulfide liquidis available from Diversified Products Manufacturing Inc., part numberDBF II. It is a suitable material for applications where motor fuels areto be encountered. Polysulfide has been used for years to coat theinside of fuel cells in aircraft.

FIG. 3 also shows an expanding compression ring 14. While the expandingcompression ring 14 is not required, the preferred embodiment uses theexpanding compression ring 14 to apply mild pressure to bonding surfaceA 18 while the bonding agent is curing. After the bonding agent hascured, approximately 30 minutes in the preferred embodiment, theexpanding compression ring 14 may be removed and used on the nextinstallation. The expanding compression ring 14 may be made of anysuitable material, plastic, metal or wood etc.

The band clamp 16 in FIG. 3 is used to tighten the liner 30 to the tankriser 28. In the preferred embodiment the liner 30 is bonded to theriser then clamped to hold the liner 30 to the tank riser 28 whilecuring. The band clamp 16 while not essential is preferred. Any properlysized all stainless band clamp 16 in the market today will work for thisapplication. Such a clamp is available from Norton Industries Inc., partnumber 035BR072-04, which fits 4″ tank risers.

FIG. 4 shows the cross section of a spill container to be repaired andthe areas requiring preparation prior to the installation of the liner30. The liner 30 may be bonded to the spill containment snow plow ring22 at bonding surface A 18. A second bonding surface B 34 is located onthe tank riser 28. These surfaces, if bonded, require proper preparationfor the bonding agents to be used. The preparation and bonding agentused is a function of the materials selected to manufacture the liner30. In the preferred embodiment a Methyl Methacrylate is used. One suchmaterial is manufactured by available from Weld On, part number SS218Stock # 30110. It is anticipated that other bonding agents will be foundthat will perform as well as or better than the currently preferredproduct. Surface preparation for the preferred embodiment includessanding bonding surface A 18 then cleaning with tetrachloroethylene.When the surfaces are clean and dry the bonding agent may be applied tothe mating surfaces to be bonded. The drain valve 26 must be removed andthe resulting hole plugged. Use a plug 40 with the same thread patternas the removed drain valve 26. The plug 40 may be made of any materialas it will be covered with a fill 38 during the installation process.

FIG. 5 is a cross section of the bellows 20 style spill container wherefill 38 has been added to cover the irregular shape of the bottom of thespill container. It should be noted that the connection between thespill container and the tank riser 28 varies by manufacturer. Most spillcontainers have bolt heads that connect the bellows 20 to the bodyand/or some sort of compression coupling or screwed coupling or othermeans for joining the tank riser 28 to the spill container. Theseconnection methods create an uneven surface at the bottom of the spillcontainer. In order to make the repair easier, it is recommended thatthe uneven bottom of the spill container be leveled. The preferredembodiment of the invention uses a liquid form of polysulfide to fill 38the bottom to a level above any irregularities encountered. Thepreferred polysulfide is a two part chemical that when mixed forms apermanent barrier to most fuels and bonds to metal and the liner 30materials in the preferred embodiment. The preferred fill 38 material isavailable from Diversified Products Manufacturing Inc., Oroville, Calif.part number DBF II. While the fill 38 is not mandatory it is recommendedin the preferred embodiment. Any liner 30 not using a fill 38 is subjectto unnecessary wear and premature failure. Manufacturing a unique liner30 for each manufacturer of spill container may be undertaken. Howeverthe tooling for this process would be unduly costly.

The cross section of FIG. 5 shows the spill container ready for theapplication of the bonding agent to the tank riser 28 and the subsequentinstallation of the liner 30. The surface of the tank riser 28 locatedunder the clamping area should be cleaned prior to applying the bondingagent. Typically the tank risers are steel. When the riser is clean,apply the bonding agent to the bonding surface B 34 for approximately1½″ above the polysulfide fill 38. The entire perimeter of the tankriser 28 should be covered with the bonding agent.

FIG. 6 is a cross section view of the liner 30 ready to be installed ina bellows 20 style spill container. In this embodiment, the liner top 12and liner bottom 10 are shown as one piece. The liner 30 may be made upof one, two pieces, as shown in the preferred embodiment, or as manypieces as necessary to match the liner 30 to be spill container. In thepreferred embodiment, the liner top 12 and liner bottom 10 and arejoined together using a solvent welding process. The material used tomanufacture the liner 30 is dissolved in a strong solvent, such astetrahydrofuran, forming a pregnant solution. When this solution isapplied to the mating and preferably overlapping surfaces of the linertop 12 and liner bottom 10, a solvent weld is created. The process ofsolvent welding is common knowledge and need not be reiterated here. Thewelded seam thus created is as strong as the liner top 12 or linerbottom 10. The liner 30 is collapsed when installed into the spillcontainer shown in FIG. 6.

FIG. 7 is a cross section view of a bellows 20 style spill containerwith the liner 30 the installed. The top of the liner 30 should mate tothe inside of the spill container's snow plow ring 22. The applicationof the bonding agent to bonding surface A 18 is applied at this time byfolding down the collapsible liner 30 and running a bead of the bondingagent around the perimeter of the liner top 12 and mating surface of thesnow plow ring 22. The top of the liner 30 may be held in place by anexpanding compression ring 14 while the bonding agent cures. Aftercuring of the bonding agent, the repair of the spill containment manholeis complete.

Since other modifications and changes varied to fit particular operatingrequirements and environments will be apparent to those skilled in theart, the invention is not considered limited to the example chosen forpurposes of disclosure, and covers all changes and modifications whichdo not constitute departures from the true spirit and scope of thisinvention.

Having thus described the invention, what is desired to be protected byLetters Patent is presented in the subsequently appended claims.

1. A liner for spill containment manholes for repairing existing leakingspill containment manholes or to provide double wall protection for newor existing single wall spill containment manholes, comprising: meansfor containing spilled fluids.
 2. The liner for spill containmentmanholes in accordance with claim 1, wherein said means for containingspilled fluids comprises a flexible membrane that may be collapsed whilebeing installed into the spill container, has a surface for attaching tothe snow plow ring, has a surface for attaching to the tank riser, isfuel resistant, may be coated with a highly fuel resistant material, maybe manufactured with one or more sections that are bonded together tocreate the liner.